Pile fabric and method of making same



June 27, 1939. H. l.. sHUTTLEwom-H 2,164,090

PIL `FABRXC AND METHOD OF MAKING SAIE Filed F'eb. 23, 1959 INVENTOR ATTORNEY5 Patented `lune 27,1939

UNITED STATES PATENT ori-TCE PILE FABRIC AND METHOD OFMAKING SAME Application February 23, 1939, Serial No. 257,904

15 claims.

This invention relates to woven pile fabrics, such as rugs and carpets, in which the pile is formed by the use of wires inserted in the shed during the Weaving operation to produce pile loops. More particularly, the invention is concerned with a novel fabric of the type referred to in which an embossed or relief effect is obtained in the pile surface by means of loops of different heights, and a new method of producing such a fabric.

In looms of the type in which pile wires are used, the Wires are inserted in the shed between the warps used in forming the body of the fabric and the pile Warps, and are beaten up by the lay and bound in place by loops of the pile warp` yarns. In the weaving operation, each Wire remains in the `fabric until a number of others have been inserted behind it, whereupon, it is withdrawn from the fabric, advanced tothe head of the series. and again inserted in the open shed. In the production of such fabrics, the pile surface may be given a design or pattern by the vuse of pile warp yarns of different colors which are raised at selected points to form loops by a jacquard mechanism. Also, the loops may be left in their original condition upon withdrawal of the wires or they may be cut by knife edges on the wires during withdrawal of the latter.

the construction referred to by `the use of pile wires of different heights. Thus, the pile yarns used to produce the pile loops in the ground area may be formed by wires of one height and the loops in the figures or in parts of the figures of the design may be formed by means of wires of a different height. Fabrics thus produced are objectionable, however, because in a single transverse row of loops, the loops must be all of the same height, since they are all formed on the same wire. As it is impossible, in such a loom, to obtain pile loops of different heights in the same transverse row, these fabrics containspaces devoid of tufts in those rows which pass through areas where the pattern requires tufts of dif ferent heights. The presence of such spaces in the pile surface detracts from the appearance of the fabrics and has reduced the sales possibillties thereof.

Attempts have been made to overcome the dif-` finished, the pile surface is treated to modify the twist in certain of the pile loops. Such treatment causes some loops either to sink below `or to rise above the loops not affected by the treatment and the resulting pile surface is made up of loops of` dierent heights. While this method permits the production of a fabric having pile loops of different heightsin the same row, it does not provide positive control of the height of the loops, since all the loops will not respond in like manner to the treatment by which the twist is modified.

The presentinvention is, accordingly, directed to the provision of a new pile fabric having a pile surface embodying relief effects, which is free of the objections to which the prior fabrics are subject, and a novel method by which the fabric of the invention may be produced in a practical and economical manner. The new fabric is superior to prior fabrics in that each transverse row of loops contains its full complement and these loops may be of different heights. Also, the formation of the loops throughout the fabric is so controlled that loops of different heights are accurately produced at selected l type of loom modified by the use of wires of a Heretofore, fabrics embodying relief effects in' the pile surface have been produced on looms Cof novel form and by employing a pattern of appropriate type, the wires being utilized in conl junction with `the jacquard mechanism to produce the desired effects in the finished goods.

The novel wires referred to are of uniform height throughout the portion of their length on which the pile loops are formed, but that end of each wire which is last withdrawn from the loops is of increased height. As the pile warp yarns are laid over such a wire and the latter is bound in place by the yarns, a row of. loops of uniform height is formed, and onA withdrawal of this wire, each loop is enlarged in order to pass over` the high end of the Wire. If such a loop is formed of. a yarn which has previously been embedded in the fabric, the additional length of yarn required for the increase in height of the loop is obtained by the stretch of the embedded portion of the yarn. If the loop to be enlarged is the second in a longitudinal series of loops made of the same yarn,l the additional length for increasing the height of the loop is obtained by reduction in the height of the preceding loop. Thus, in `a longitudinal series of loops of the same yarn, the withdrawal of each wire increases the height of the loop formed over it and in doing so results in either stretching the embedded portions of the yarn or decreasing i:he height of the preceding loop of the yarn. When the wire in the last loop in such a series, immediately precedingan embedded portion of the yarn, has been withdrawn, leaving the loop with an increased height, this last loop retains that height, and, as consequence, throughout the fabric. each pile area of a single color or type of yarn is outlined along the margin last formed by loops of greater height than those within the area. By employing two or more pile forming yarns'of different colors or types and providing loops of increased height in the fabric Just before a change ln the yarns, the embossed or relief effect above referred to is produced.

For a better understanding of the invention reference may be had to the accompanying drawing, in which: l y

Fig. 1 is an enlarged longitudinal view in section showing one form of the new fabric in the process of manufacture and illustrating the manner in which the pile loops bind the wires in the fabric before the wires are withdrawn;

Fig. 2 is a side view of the end portion of a pile wire used in making the new fabric;

Figs. 3 and 4 are enlarged longitudinal views in section of part of the fabric shown in Fig. 1 illustrating the formation of the high and low pile loops on withdrawal of the pile wires;

Fig. 5 is a view similar to Fig. 1 illustrating the fabric after the withdrawal of the wires and showing the'relation of the long and short pile loops which form the high and low pile areas in the pile surface to produce the embossed or relief eifect of the invention, and

Fig. 6 is a perspective view of a piece of iinished fabric made in accordance with the invention.

The backing of the fabric may be of any suitable construction, but in the form illustrated is of the two-shot Wilton type including stuifer warps I0 and two series of weft threads I I and I2 lying, respectively, above and below the stuiier warps and bound in place by two sets of binder warps I3 and I4. Pile forming yarns II, I8 and I'I are extended along the fabric in the body thereof between the stuifer warps and the upper series of weft threads I2, until they are selected by the Jacquard mechanism (not shown) and raised over pile wires I8 to 32, inclusive, to form the pile loops. The yarns l5, I C and I1 are preferably of contrasting appearance, as for example. of different colors, depending on the pattern which is desired. It will be understood that the backing of the fabric may be woven in any suitable manner other than that shown to furnish a proper support for the pile loops. For example, the backing may consist of a single set of binder warps or may have three sets of weft threads for each pile loop. Also, the number of pile forming yarns may be varied in accordance with the desired pattern.

'I'he weaving of the fabric may be conveniently performed in the standard Wilton type of loom employing a jacquard for controlling the pile yarns but modified by the use of pile wires which are of increased height at one end, as shown in Fig. 2. The wire there shown includes the usual body portion a, which may be of any desired height, and an end portion b which is somewhat higher than the body portion and is generally spoon-shaped. In the drawing, I have shown a series of fifteen of these wires bound in the fabric` in the weaving operation by the pile forming yarns I5, It and II which are looped over the wires.- It willv be apparent. however, that the numbenof wires in the series may be varied.

In the weaving operation, the jacquard raises one of the yarns, such as the yarn l5, for example, from the body of the fabric under the weft threads I2, and the first Wire Il is inserted in the shed formed by the raising of this yarn. after which the yarn Il is looped over the wire I8 by the lowering of the yarn strands to pass under the next upper weft thread. In a like manner, according to the pattern desired, wires I 9, 20 and 2l are inserted in the sheds formed by the raising of yarn I l, and when the yarn is looped over wire 2i itis returned to the body of the fabric and extended along within the body for some distance. After the yarn I5 is passed over wire 2| and back into the fabric, the jacquard raises another of the yarns, the yarn I6, for example, and passes it successively over the wires 22 and 23, after which it is returned to the body of thc fabric. Then, according to the pattern, the Jacquard selects another yarn, such as the yarn I5, which is successively looped over wires 24 to 21, inclusive, and passed back into the body of the fabric. The next selection by the jacquard causes yarn I6, for example, to be looped successively over wires 28 and 29, and in a like manner a different yarn, such as the yarn I1, is then looped over wires 3l, 3| and 32. All of the wires in the series are nowinserted in the fabric so that on each wire a transverse row of loops extends over the body portion a, the end portion b of the wire extending beyond the loops.

- Ihe cycle is now repeated by withdrawing theV first inserted wire Il and inserting it again in the shed which is formed immediately after the insertion of the last wire 32 of the series, as shown in dotted lines inI Fig. l. Similarly, the wire I9 is withdrawn from the loops, and inserted in the shed which is formed immediately after the insertion of wire I8 in its etc.

In withdrawing the wire I8 from its initial position in the fabric, the loops on it are forced to pass along the wire over the end portion 'o and in so doing are stretched from a height corresponding to the body portion a to a height corresponding to the end portion b of the wire. In this stretching of the loops, the yarn I5, in the longitudinal row of loops shown in Fig. 1, is drawn from under the previously inserted weft thread I2, and sufficient yarn is thus obtained to form the loop itc of a height substantially the same as the height of the end portion b of the wire. When the next wire I9 is withdrawn, theloops thereon arel caused to stretch in a similar manner from a height corresponding to the body portion a to a height corresponding to the end portion b of vthe wire, and in this stretching, the yarn strands are drawn from under the previously inserted weft thread with the result that the height of the loop Ilc is reduced to a height Il', as shown in Fig. 4. At the same time, the enlarged loop Ild is formed which is substantially the same height as the previously formed loop Ilc. The wires are thus withdrawn successively and re-inserted, as described, but when a wire immediately preceding a yarn change is withdrawn, such as the wire 2|, the loop of increased height which it leaves retains that height because the yarn necessary to increase the height of the next loop 22' in the same longitudinal row is obtained, not from the loop 2|' preceding it, but from the embedded portions of the new yarn It.

new position,

20' are of the same height, while loop 2|', whichis the last loop formed prior to a yarn change, is higher than the loops Il' to Ill' and corresponds substantially to the height` of the end portion bof the previously withdrawn wire. Throughout the fabric, therefore, the last loop formed prior to a yarn change is a high loop, and the preceding loops from the same yarn strands are low loops. IThus. as shown in Fig. 5, there is a yarn change immediately following loops 2|', 23', 21', 2i', 32' and I9", and accordingly the latter loops are higher than the others illustrated. It will be understood that the order of the yarn changes in the longitudinal rows of loops in the fabric may vary in different rows, depending on the desired pattern. Also, while the loops are shown as uncut after withdrawal of for example. by means of cutting edges on` the wires which sever the yarns asthe wires are withdrawn.

By the practice of the new method, the ground pile area of the yfabricrnay be formed of loops of a relatively low height and the pattern area may beoutlined at as many points as desired by loops of a greater height. Whilethe design to be woven is preferably selected so that at least two loops are formed before each yarn change, thereby permitting the formation of a high loop by reducing the height ofthe preceding loop, it is possible to form a single high loop immediately following a yarn change. Thismay be accomplished by using a yarn having suiilcient stretch or elasticity to allow the loop to expand and thus pass over the high end portion b of the pile wire when there are no immediately preceding loops of the same yarn from which to draw the extra material. vy It will be apparent that with the new method it is possible to obtain any combination of vhigh and low pile loops in a transverse row of the fabric, depending on the selection of thepile` yarn by the jacquard: The novel fabric of the invention is produced with a pleasing embossed or relief effect and is superior to prior fabrics in that it does not have spaces devoid of tufts.

`Since the pile wires employed may be of the same height, the new fabric may be produced eilieiently and at low cost and, in addition, with an accurate control of the height of the tuft loops. vAny desired relationship in the heights of thelow and high loops may be readily obtained tion of stutter warps, weft shots lying above and` below the stuffer warps, binder warps crossing the weft shots above and below and binding the Aweit shots inplace,'and a plurality of sets of pile warps held in place by. portions lying between the upper and lower weft shots. other portions of the pile warps being raised between adjacent upper weft shots in accordance with a pattern to provide loops lying in rows extending transversely of the fabric, each row containing a full complement of loops and certain of the rows containing loops of different heights.

2. A pile fabric which comprises the combination of stuffer warps, weft shots lying above and below the stuifer warps. binder warps crossing the weft shots above and below and binding the weft shots in place, and a plurality of sets of pile warps of different colors held in place by portions lying between the upper and lower weft shots, other portions of the pile warps being raised between adjacent upper weft shots in accordance with a pattern to provide loops in pile areas of different colors, the loops along the end margins of the areas longitudinally of the fabric being of different height from those inward from said margins. 3. A pile fabric which comprises the combina tion of stuffer warps, weft shots lying above and below the stuffer warps, binder warps crossing the weft shots above and below and binding theweft shots in place, and a plurality of sets of pile warps of different colors heldin place by portions lying between the upper and lower weft shots, other portions of the pile warps being raised between adjacent upper weft shots in accordance with a pattern to provide loops 'in pile areas of,

different colors, the loops along the margins of the areas being higher than those spaced from said margins. l

4. A pile fabric which comprises the combination of stuffer warps, weft shots lying above and below the stuifer warps, binder warps crossing the weft shots above and below and binding the weft shots in place, and a plurality of sets of pile warps of different colors heldin place by portions lying between the" upper and lower weftv shots, other portions of the pile warps being raised between adjacent upper weft shots in accordance with a pattern to provide loops forming a pile surface, the loops at the points of color change being higher than those elsewhere.

5. A pile fabric which comprises the combination of stuifer warpsweft shots lying above and below the stuier warps, binder warps crossing the weft shots above and below and binding the weft shots in place, and a plurality of sets of pile warps held in place by portions lying between the upper and lower weft shots, other portions of 'the pile warps being raised between adjacent upper weft shots in accordance with a pattern to provide loops, the last loop in any longitudinal series of loops of a single pile warp yarn being higher than Athe other loops in said series.

. 6. A pile fabric which comprises the combination of stuier warps, weft shots lying above and below the stuifer warps. binder warps crossing` the weft shots above and below and binding the weft shots in place, and a plurality of sets of pile-warps held in place by portions lying between the upper and lower weft shots, other portions of the pile warps being raised between adjacent upper weft shots in accordance with a pattern to provide loops lying in rows extending transversely of the fabric, each row containing a full complement of loops, and the last loop in any longitudinal series of loops of a single pile warp yarn being higher than the other loops in said series.

7. A pile fabric which comprises' the combination of stuffer warps. weft shots lying above and below the stuifer warps, binder warps crossing the weft shots above and belowr and binding the weft shots in place, and a plurality `of sets of pile warps, each pile warp yarn having portions lying between the upper and lower weft shots and other portions raised between adjacent upper wefts in accordance with a pattern to provide loops, the pile surface formed by theloops having areas formed by loops of pile warp yarns of a single set, each area including loops along its margin last formed which are higher than the loops formed of the same yarns within the area,

8. A method of makina a pile carpet or mat having a backing and a plurality of sets of pile warps, which comprises forming the backing with the pile warps held therein by parts of said backing, raising thepile warps selectively from the backing in accordance with a pattern and lowering the raised warps about pile wires and restoring them to the backing to provide longitudinal rows of loops of a single height, increasing the height of the loops in each transverse row, and then reducing the height of only those loops in said row which are directly followed in their respective longitudinal rows by loops of the same pile warp.

9. A pile carpet or mat comprising backing; and a pluralityv of sets of pile warps eid within the backing in generally parallel r including a plurality of pile w of contrasting appearance, said warps being raised selectively from the backing in accordance with a pattern to provide longitudinal rows of loops forming a pile surface, the last loop in any longitudinal series of loops of `a single pile warp being higher than the other loops in said series.

10. A method of weaving a pile fabric includ- 4ing stuffer warps, binder warps, weft shots, and

a plurality of- 'sets of pile warps, which comprises manipulating the several warps to form successive sheds, inserting the weft shots in the sheds both above and below the stuiier and pile warps and in position to be bound in place by the binder warps, raising the pile warps between adjacent upper weft shots in accordance with a pattern and lowering the pile warps about pile wires to provide loops of a single height, and

subsequently reducing the height of all loops except the last in each longitudinal series of loops made of the same pile warp.

11. A method of weaving a pile fabric including stuiler warps, binder warps, weft shots, arid a plurality of sets of pile warps, which comprises.

manipulating the several warps to 'form successive sheds, inserting the weft shots in the sheds both above and below the stuifer and pile warps and in position to be bound in place by the binder warps, raising-the pile warps between adjacent upper weft shots in accordance with a pattern and lowering the pile warps about pile wires to provide loops of a single height, increasing the height ofthe loops in each transverse row, and then reducing the height of selected loops.

12. A method of weaving a pile fabric including stuer warps, binder warps, weft shots, and a plurality of sets of pile warps. which coms, each set Valumno prises manipulating 'the several warps to form successive sheds.inserting the'weft shots in the shedsboth above and below the stuifer andpile warpsandinpositiontobeboundinplaceby the binder warps,rsising the pile warps betweeny adjacent upper weft shots in accordance with a pattern and lowering the pile warps about pile wires to provide loops of a single height, increasing the height oi.' the loops in each transverse row, and subsequently reducing the height of all loops within an'ares representing a pattern iigure except the loops last produced in said area and lying along a margin thereof.

`13. A method of weaving a pile fabric including stuifer warps, binder warps, weft shots, and a plurality of sets of pile wlrp. which' comprises manipulating the several warps to form successive sheds, inserting the weft shots in the sheds both above and below the stuner and pile warps and in position to be bound 'in place by the binder warps, raising the pile warps between adjacent upper weft shots in accordance with a pattern and lowering the pile warps about pile'wires to provide loops of a single height, and subsequently reducing the height of all loops except the last formed consecutively of a single pile warp.A

14. A method of weaving a pile fabric including stuil'er warps, binder warps. weft shots, and a plurality of sets of pile warps, which comprises manipulating the several warps to form successive sheds, inserting the weft shots in the sheds both above and below the stuifer and pile warps and in position to be bound in place by the binder warps. raising the pile warps between adjacent upper weft shots in accordance `with a pattern and lowering the pile warps about pile wires .to provide loops'of a single height, and

subsequently reducing the height of all loops lying in a liney lengthwise of the fabric except the loop immediately preceding a color change in said line.

l l5. A method of weaving a pile fabric including stuifer w'arps.- binder warps, weft shots, and a plurality of sets of pile warps, which comprises manipulating the several warps to form successive sheds, inserting the weft shots in the sheds both above and belowthe stufier and pile warps and in position to be bound in piace by the binder warps, raising the pile warps between adjacent upper weft shots in accordance with a pattern and loweringthe pile warps about pile wires to provide loops of a single height, increasing the height of loops 'in each transverse row, and withdrawing material from selected loops for use in the formation of subsequent loops.

HOWARD L. SHUTTLEWOR'I'H. 

